Pic. 6.25. Front brake components
Removing the brake pads
Drain the brake fluid.
Attention! When replacing brake pads, always change the inner pads, outer pads and pad covers as a set.
Remove the front wheel and temporarily secure the rim with two nuts.
Turn away a bolt and disconnect an arm of a brake hose.
Pic. 6.26. Loosening the caliper bolts
While holding the guide pins, unscrew the caliper mounting bolts (pic. 6.26).
Raise the caliper and secure it with wire.
Pic. 6.27. Brake pad components: 1 - anti-creak plate; 2 - anti-creak gasket; 3 - brake pads; 4 - pad wear indicators
Remove two anti-squeak springs, two brake pads, two anti-squeal pads holding plate liners (pic. 6.27).
Pic. 6.28. Removing pad wear indicators
Using a thin-blade screwdriver, remove the pad wear indicators (pic. 6.28).
Pic. 6.29. Removing the guide pins from the caliper
Remove guide pins from caliper (pic. 6.29).
Pic. 6.30. Removing the o-ring from the guide pin
Using a thin-blade screwdriver, remove the O-rings from the guide pins (pic. 6.30).
Attention! When removing the seal, do not damage the guide pin housing.
Pic. 6.31. Removing the caliper
Loosen the caliper housing mounting bolts and remove the caliper (pic. 6.31).
Pic. 6.32. Removing the guide pin boots
Holding the caliper in a soft-jawed vice, use a screwdriver and hammer to remove the guide pin boots (pic. 6.32).
Pic. 6.33. Removing the brake cylinder boot
Using a screwdriver, remove the brake cylinder boot spring ring and boot (pic. 6.33).
Place a rag between piston and cylinder.
Pic. 6.34. Removing the piston from the cylinder
Using compressed air, remove the piston from the cylinder (pic. 6.34).
Pic. 6.35. Removing the gland
Using a screwdriver, remove the seal (pic. 6.35).
Checking the brake pads
Pic. 6.36. Measuring the thickness of brake pads
Measure the thickness of the brake pads with a ruler (pic. 6.36).
- Standard thickness: 12 mm.
- Minimum thickness: 1.0 mm.
Checking the brake disc and brake components
Check for corrosion, wear and damage on the inner walls of the cylinder. Replace cylinder body if necessary. Minor imperfections caused by corrosion or foreign particles can be removed by sanding the surface with fine emery cloth. Replace cylinder body if necessary. Check for wear, cracks and damage. If necessary, replace the corresponding component. Check for corrosion, wear and damage on the piston surface. If necessary, replace the corresponding component. Check for corrosion, wear and damage on the guide pin and guide pin boot. If necessary, replace the corresponding component. Check for uneven wear, cracks and severe damage to the surface of the brake disc.
Measuring the thickness of the brake disc
Pic. 6.37. Measuring the thickness of the brake disc
Using a micrometer, measure the thickness of the brake disc (pic. 6.37).
- Standard Thickness: 28mm
- Minimum Thickness: 26mm
Replace the disc if the disc thickness is less than the minimum allowable.
Measuring brake disc runout
Pic. 6.38. Marking the hub axle bushing and brake disc
Mark the brake disc and wheel hub axle bushing (pic. 6.38).
Attach the brake disc to the wheel hub with wheel nuts (in 2 or more places).
Pic. 6.39. Checking disc runout with an indicator
Check the beat with an indicator (pic. 6.39).
- Measuring point: 10 mm from the outer edge of the disc.
- Maximum runout: 0.05mm or less.
Attention! Make sure the end play is 0 mm before taking a measurement.
If the runout is significant, find the point of minimum runout by successively shifting the installation position of the brake disc on the hub by one hole.
Assembly
Pic. 6.40. Installing the seal in the piston
Apply lithium rubber grease to the piston seals and install them in the cylinder body (pic. 6.40).
Attention! When installing, do not use too much force, so as not to damage the parts.
Pic. 6.41. Installation of a spring ring and a cover of the brake cylinder
Install the brake cylinder boot circlip and boot (pic. 6.41).
Pic. 6.42. Installing the guide pin boots
With socket wrench (19mm) and hammer, install the guide pin boots (pic. 6.42).
Lubricate the anthers with lithium grease first.
Install the brake cylinder housing on the brake disc and tighten the fixing bolts.
Tightening torque: 103 N.m.
Install guide pins.
Install the brake pads.
Install the support.
Tighten the mounting bolts.
Tightening torque: 34 N.m.
Install the brake hose and tighten the fastening nut.
Tightening torque: 29 N.m.
Pour brake fluid into the barrel.
Check if brake fluid is leaking from the master cylinder.
Check the pipes and hoses of the brake system.
Pump the brakes.
Install wheels.